Apparatus for closing and stapling cartons varying in size



March 24, 1970 H. A. BouLAY ETAL 3,502,256

APPARATUS FOR CLOSING AND STAPLING CARTONS VARYING IN SIZE Filed Dec. 8, 1966 17 Sheets-Sheet 1 INVENTORS f/mre/ flzaazaw 75x 1, 674 w? BY 44% mm ZTTORNEYS March 24, 1970 H. A. BOULAY ETAL 3,502,256

APPARATUS FOR CLOSING AND STAPLING CARTONS VARYI NG IN SIZE Filed Dec. 8, 1966 17 Sheets-Sheet 2 March 24, 1970 H. A. BouLAY EI'AL 3,502,256

APPARATUS FOR CLOSING AND STAPLING CARTONS VARYING IN SIZE Filed Dec. 8, 1966 17 Sheets-Sheet 5 INVENTOR5 1%)1/8/ fl. Iowa 4 Y ATTORNEYS March 24, 1970 H, BOULAY ETAL 3,502,256

APPARATUS FOR CLOSING AND STAPLING CARTONS VARYING IN SIZE Filed Dec. 8, 1966 1'7 Sheets-Sheet 4 wv' 'lll 2 4 9 MM M j i I] 7% I I I I l I I I I'l INVENTORS 152-2467 A 30044 ll si 9574 1 4 v BY zxwfl zaw I ATTORNEYS March 24, 1970 H. A. BOULAY T 3,502,256

APPARATUS FOR CLOSING AND STAPLING CARTONS VARYING IN SIZE Filed Dec. 8, 1966 17 Sheets-Sheet 5 g k v '7 54 J4 I INVENTORS EZ-WK/ /9 5004/2) daasfw/ 5/4 169 ATTORNEYS March 24, 1970 H. A. BOULAY ETAL 3,502,256

APPARATUS FOR CLOSING AND STAPLING CARTONS VARYING IN SIZE Filed Dec. 8, 1966 17 Sheets-Sheet 6 /Z/ 60 o000oooO0 F7 7 a 0 773 [Z3 k4 i w I N VEN TORS March 24, 1970 H. A. BOULAY ETAL 3,502,256

APPARATUS FOR CLOSING AND STAPLING CARTONS VARYING IN SIZE Filed Dec. 8, 1966 17 SheetsSheet '7 4. ATTORNEYS 5448/ 6330mm @55 03/4 r4 March 24, 1970 H. A. BOULAY E 3, 0

APPARATUS FOR CLOSING AND STAPLING CARTONS YARYING IN SIZE Filed Dec. 8. 166

I 17 Sheets-Sheet 8 March 24, 1970 H. A. BOULAY Em 3, 0

APPARATUS FOR CLOSING AND STAPLINGCARTONS VARYING IN SIZE File'd Dec. 8, 1966 l7 SheetsSheet 3 INVEN'iORS M ATTORNSS March 24, 1970 H. A. BOULAY ETAL 3,502,256

APPARATUS FOR CLOSING AND STAPLING CARTONS VARYING IN SIZE Filed Deb. a, 1966 17 Sheets-Sheet 12 72 HQ /4 a b 2 IWd 4%.:

INVENTOR$ ATTORNEYS March 24, 1970 H. A. BOULAY ETAL 3,502,256

APPARATUS FOR CLOSING AND STAPLING CARTONS VARYING IN SIZE Filed Dec. 8, 1966 mvmons fiwe/ 0. 3004 4 Y /Zsffifl 5/4 :09

BY v 44m ATTORNE'Y5 l7 Sheets-Sheet 13 March 24, 1970 H. A. BO-ULAY ETAL 3,502,256

APPARATUS FOR CLOSING AND STAPLING CARTONS VARYING IN SIZE Filed Dec. 8, 1966 17 Sheets-Sheet 1L INVENTORS ATTORNEYS Marph 24, 1970 H. A. BOULAY ETAL 3,502,256

I APPARATUS FOR CLOS ING AND STAPLING CARTONS VARYING IN SIZE Fild Dec.-8. 1.966

1'7 Sheets-Sheet 15 ATTORNEY$ United States Patent Q 3,502,256 APPARATUS FOR CLOSING AND STAPLING CARTONS VARYING IN SIZE Henri A. Boulay, West Warwick, and Joseph Silva, Cranston, R.I., assignors to Bostitch Division of Textron, Inc., East Greenwich, R.I., a corporation of Rhode Island Filed Dec. 8, 1966, Ser. No. 600,163 Int. Cl. B2lj 15/28; B27f 7/06; B25c 5/00 US. Cl. 2277 10 Claims ABSTRACT OF THE DISCLOSURE The specification discloses an apparatus for closing and stapling cartons of varying sizes of the type having a pair of end flaps and a pair of side flaps, which when opened are disposed in a coplanar relationship with respect to the side walls of the carton, the dimensions of the flaps measured in the direction of the outward extent thereof being generally equal to one half the width of the carton. The apparatus includes means for automatically feeding successive open-topped cartons of varying size through the apparatus, during which a flap closing mechanism is operable to close the open top flaps and a staple driving means is operable to drive staples into the closed top flaps to secure them in a closed relation. The staple driving means cooperates with the conveying means for moving successive cartons through the apparatus and with a carton width sensing means to automatically position the carton in stopped relation with respect to the staple driving means in a plurality of different positions at which staples are driven, the arrangement being operable to automatically drive staples into the side flaps and the underlying end flaps only of each successive carton at positions spaced longitudinally in accordance with the width of the carton, the staples associated with each end flap being spaced apart a distance not exceeding a predetermined distance and at least one of which is within approximately one inch from the adjacent end of the carton.

This invention relates to container closing and sealing machines and more particularly to apparatus for automatically closing the flaps of successive cartons of various sizes and sealing the flaps in closed relation with fasteners, such as staples or the like.

In the packaging industry, fiberboard cartons have been used for many years and various machines have been developed which are capable of closing the flaps of the carton after the carton has been filled and of sealing the carton either by gluing the flaps, taping the flaps, or by stapling or otherwise providing mechanical fasteners to maintain the flaps in closed relation.

When dealing with standard fiberboard cartons of the type including side flaps which, when folded into closed relation, meet or substantially meet along their free edges in a vertical plane passing through the longitudinal axis of the carton, it is important to provide staples which bridge the free edges of the side flaps and extend within or through the end flaps disposed therebelow. Depending upon the length of the carton, there may be a substantial gap between the free edges of the end flaps and within the area of this gap no staples are required as they are considered to be inefiective in securing the carton in closed relation.

Machines which are capable of automatically accommodating any size carton of the above mentioned standard type within a predetermined range which are fed thereto have been proposed. Such machines conventionally include a carton conveying mechanism which is ca- 3,502,256 Patented Mar. 24, 1970 "ice pable of receiving filled open cartons and conveying them to a stapling station during which movement the open top flaps are closed. Such prior art machines embody means for automatically accomplishing a stapling cycle which may include stopping the conveying mechanism when the carton is at a first stapling position, actuating the stapling heads while the carton is stopped, and then restarting the conveying mechanism. The stapling cycle is then automatically repeated at predetermined stapling positions.

In the machines heretofore proposed, the stapling positions at which the staples are driven into the end flaps of the carton are determined by means engageable with the leading end and trailing end of the carton at predetermined fixed position of movement. Consequently, with this arrangement the positions of the staples in the end flaps are fixed and cannot be automatically varied to accommodate variations in the size of the end flaps of the cartons fed to the machine. Where the cartons to be sealed are intermixed as to size, this lack of automatic accommodation introduces considerable down time for manual adjustment, materially reducing the efficiency of the machine.

The Uniform Freight Classification Code includes quite exacting specifications as to the positions of staples in the end flaps of a carton to obtain an approvable securement. For example, the code specifies that staples must be positioned within the end flaps at each end of the carton within an approximate one inch maximum distance, and that the maximum spacing between adjacent staples within each end flap must not exceed five inches. Moreover, it is desirable to position staples in the end flaps adjacent their free edges, as, for example, within a spacing of a maximum of approximately one inch from the free edge.

It can thus be seen that these optimum and required conditions as to the positioning of the staples in the end flaps cannot be obtained in a Wide range of varying box size widths by simply fixing the spacing between the stapling positions for each end flap as is the case with prior art machines. For example, if the machine is set up to drive two staples at two fixed positions; one, approximately one inch from the end, and the second approximately two inches from the first, it can be seen that as the size of the end flap increases a substantial area adjacent the free edge of each end flap will remain unstapled. A twelve inch end flap would have no staple within the area nine inches from its free edge and this condition would increase as the size of the end flap increases. Attempts to alleviate this condition by reducing the fixed distance between adjacent staples to thereby compensate for the larger cartons invariably lead to the utilization of more staples than necessary, thus materially increasing the staple costs and the time required to effeet the stapling operations. Consequently, the machines of the prior art are either severely limited in the size range of the cartons which can be accommodated or over compensate in order to provide sufficient staples to accommodate a greater range thereby decreasing efficiency as to the optimum number of staples used and the time required to effect the stapling operation.

An object of the present invention is the provision of a machine for automatically stapling the flaps of a carton in closed relation having means for automatically varying the position at which the staples are secured within the end flaps of the carton to accommodate variations in the end flap size of the cartons fed to the machine.

In accordance with the principles of the present invention, this object is accomplished by initially sensing or measuring the width size of the box fed to the machine and of varying the location of the means which determines the position at which the staples are driven into the carton in accordance with the width of the carton measured or sensed. Standard cartons are such that the extent of the end flaps in the longitudinal direction with respect to the carton when in closed condition is equal to one-half of the width of the carton, since this dimension of the end flaps is equal to the transverse extent of the side flaps when closed and this dimension of the side flaps is substantially one-half of the width. Consequently, by measuring the width of the box the longitudinal extent of the end flaps when closed can likewise be determined and the positions of the staples varied accordingly. Thus, a machine constructed in accordance with the present invention embodying such capability will accommodate cartons which vary in size within a greater range than the range which prior art machines can accommodate while at the same time insuring the proper positioning of an adequate number of staples in accordance with acceptable requirements.

In accordance with the principles of the present invention the variation in the positions within which the staples are driven is generally proportionate to the width of the carton. It will be noted, however, that in accommodating end flap sizes within a range of, for example, three inches to twelve inches, if three staples are provided in each twelve inch end flap with a spacing between adjacent staples of five inches, the spacing between staples in a three inch end flap would be less than one inch if a strict width proportion spacing were adhered to. Thus, where the variation is strictly adhered to in proportion to the width of the carton, one of two conditions would exist, first, in the lower size ranges, more staples would be utilized than required, or two, in the upper size ranges less staples than required would be utilized. In accordance with the principles of the invention, the optimum desired number of staples is automatically determined to be utilized in accordanc with the measured width of the carton fed thereto.

Accordingly, it is a further object of the present invention to provide a machine of the type described having means for varying the number of positions at which staples are driven into the end flaps of the carton in accordance with the measured width of the carton fed thereto.

A further object of the present invention is the provision of a machine of the type described having means manually operable for selectively rendering the machine capable of driving only a single staple into each end flap of the carton adjacent each end of the carton. While the machine of the present invention is thus capable of automatically accommodating a wide range of carton width sizes and automatically driving staples into the end flaps thereof of an optimum number and of optimum spacing to meet Uniform Freight Classification Code requirements, in some instances particularly with small width cartons where only a minimum closure of the carton is desired, or where the cartons to be closed are not subject to subsequent freight regulations, it is desirable to maintain the top and bottom flaps in closed relation simply by the utilization of two staples in the top and bottom respectively positioned adjacent each end of the carton.

A further object of the present invention is the provision of a machine of the type described having means operable in response to manual selection for rendering the machine capable of driving only a single staple into each end flap.

Another object of the present invention is the provision of a carton closing and sealing machine of the type described in which variations in the height size of the cartons fed thereto are accommodated independently at the flap folding station and at the stapling station, the flap folding mechanism being normally disposed in a lowermost position and movable into operative position to accommodate the particular height size of the carton fed thereto by movement of the carton into engagement with the flap folding mechanism by the conveying mechanism of the machine, the top stapling mechanism of the machine being normally disposed in an uppermost position and movable downwardly into an operative position to accommodate the particular height size of the carton fed thereto in response to the engagement of the stapling mechanism with the carton during its downward movement.

Still another object of the present invention is the provision of a flap folding mechanism of the type described useful in carton sealing machines of the gluing and taping type, as well as the stapling type, which embodies a powerdriven endless belt having an operative flight extending downwardly and in the direction of carton movement at a lowermost initial position so as to engage the upper leading end of the carton and the leading end flap extending thereabove during the movement of the carton by the conveying mechanism so that during the subsequent movement of the carton after engagement, the leading end flap will be folded by the operative flight by the belt into closed position and the operative flight of the belt will be moved through engagement of the upper end of the carton therewith during its movement into a rear flap folding position wherein the entire belt is disposed above the upper leading end of the carton and means for actuating the belt to drive the operative flight in a direction downwardly and in the direction of carton movement at a speed greater than the speed of carton movement so as to effect the inward closing of the trailing end flap during the movement of the carton by the conveying mechanism.

Still another object of the present invention is the provision of a top flap stapling mechanism of the type described having improved means for effecting downward movement of the mechanism from an initial position toward the top of a carton disposed therebelow, and improved means for stopping the downward movement of the mechanism in response to the engagement of the mechanism with the top of the carton The machine of the present invention embodies a pair of transversely spaced conveying mechanisms for effecting the movement of successive cartons through the machine. The conveying mechanisms each comprise endless belt assemblies which are removable toward each other from an initial position to engage the sides of a carton fed to the machine and to convey such carton through the machine. Where two opposed live belts are utilized to positively move the carton through the machine, it is important to insure that each successive carton will be properly oriented with respect to the inwardly moving live belts, otherwise the vertical walls of the carton may be distorted in the manner of a parallelogram resulting in the securement of the flaps thereto in a relationship which maintains the distorted configuration of the vertical walls.

When dealing with cartons which vary in size it is not always possible to insure that successive cartons will be delivered to the machine in proper oriented relation. For example, if the carton is fed to the machine with its longitudinal axis at an angle to the longitudinal axis of the machine, it is necessary to orient the carton so that both longitudinal axes are in alignment prior to the movement of the carton through the machine, other- Wise the condition mentioned above will take place. The conveying action of a pair of carton side engaging belt assemblies is dependent upon a tight frictional engagement between the belts and the sides of the carton and consequently, orientation of the carton after the belts have contacted the carton becomes a somewhat difficult operation since such orientation requires relative movement between the carton and the carton engaging surfaces of the belts.

Accordingly, it is a still further object of the present invention to provide a conveying mechanism of the type described having improved means for alleviating the driving frictional contact between the belt assemblies and the carton during the initial engagement of the belt assemblies with the carton as they move inwardly so as to cause the cartons to assume a properly oriented relation between the belt assemblies during their subsequent movement through the machine.

These and other objects of the present invention will become more apparent during the course of the following detailed description and appended claims.

The invention may best be understood with reference to the accompanying drawings wherein an illustrative embodiment is shown.

In the drawings:

FIGURE 1 is a side elevational view of a carton closing and stapling machine embodying the principles of the present invention;

FIGURE 2 is a sectional view taken along the line 2--2 of FIGURE 1;

FIGURE 3 is a sectional view taken along the line 3--3 of FIGURE 1;

FIGURE 4 is an enlarged elevational view of the discharge end of the machine;

FIGURE 5 is a fragmentary sectional view taken substantially along the line 55 of FIGURE 4;

FIGURE 6 is a fragmentary sectional view taken along the line 6-6 of FIGURE 5;

FIGURE 7 is an enlarged fragmentary top plan view of the carton receiving end of the conveying mechanism of the machine, illustrating the manner in which the carton orienting mechanism operates;

FIGURE 8 is a fragmentary sectional view taken along the line 88 of FIGURE 7;

FIGURE 9 is an enlarged fragmentary top plan view of the fiap folding mechanism of the machine;

FIGURE 10 is a side elevational view of the flap folding mechanism, showing the same in its normal inoperative or lowermost position;

FIGURE 11 is a view similar to FIGURE 10 showing the flap folding mechanism in its operative rear flap folding or raised position;

FIGURE 12 is a side elevational view of the top stapling mechanism;

FIGURE 13 is a schematic view illustrating the pneumatic circuit of the machine;

FIGURE 14 is a schematic view illustrating the electrical circuit of the machine;

FIGURE 15 is an enlarged fragmentary top plan view of the mechanism for varying the position at which the staples are driven into the rear or trailing end flap of the carton;

FIGURE 16 is a sectional view taken along the line 1616 of FIGURE 15;

FIGURE 17 is an enlarged fragmentary sectional view taken along the line 1717 of FIGURE 15;

FIGURES 18 through 23 are schematic top plan views illustrating various functions applied to the carton during its movement through the machine.

GENERAL CONSTRUCTION AND OPERATION OF THE MACHINE Referring now more particularly to FIGURES 1-4 of the drawings, there is shown therein a machine or apparatus, generally indicated at 10, embodying the principles of the present invention. In general, the machine includes a horizontally elongated frame assembly, generally indicated at 12, arranged to receive at one end successive open cartons and a carton conveying mechanism in the form of a pair of transversely spaced carton side engaging endless belt assemblies 14 mounted on the frame assembly 12 for movement toward and away from each other for effecting movement of successive cartons fed to the carton receiving end of the frame longitudinally to the opposite end of the frame assembly for discharge from the machine.

The machine 10 also includes a top flap folding mechanism, generally indicated at 16, mounted adjacent the receiving end of the frame for sequentially folding the leading end flap, the trailing end flap, and the side flaps of successive open cartons into closed relation during their movement through the machine by the conveying mechanism 14. The flap folding mechanism 16 also serves to maintain the top flaps in closed relation during the driving of staples therein by a top stapling mechanism, generally indicated at 18, simultaneously with the driving of aligned staples into the closed bottom flaps by a bottom stapling mechanism, generally indicated at 20.

The machine 10 includes a fluid pressure operated circuit, generally indicated at 22 (FIGURE 13), and an electrical circuit, generally indicated at 24 (FIGURE 14), for controlling the operation of the conveying mechanism 14, the flap folding mechanism 16, and the stapling mechanisms 18 and 20 through a cycle of automatic operation with respect to each carton fed thereto. This operative 'cycle includes movement of the pair of belt assemblies from a spaced apart carton receiving position inwardly toward each other to engage the sides of a carton fed to the receiving end of the frame assembly 12 to thereby move the engaged carton longitudinally through the top flap folding mechanism 16, during which movement the top flap folding mechanism is operable to sequentially fold into closed relation the leading or front end flap of the carton, the trailing or, rear end flap of the carton, and the side flaps of the carton, stopping the movement of the belt assemblies after the top flaps have been closed and when the cartoon has been moved to a first stapling position, actuating the top and bottom stapling mechanisms to drive staples into the top and bottom flaps of the carton in the first stapling position, reactuating the belt assemblies to move the carton away from the first stapling position, and repeating at a plurality of spaced stapling positions the actuations necessary to stop the movement of the carton in the respective stapling position to drive the staples into the top and bottom flaps of the carton and to move the carton away from the respective stapling position, and finally to move the belt assemblies out of engagement with the sides of the carton at the discharge end of the frame assembly after the stapling operations have been completed.

The machine 10 of the present invention is operable to automatically accommodate cartons of varying size within a predetermined size range and is adjustable to accommodate different size ranges. An important feature of the present invention is the manner in which the electropneumatic circuitry is operable to adjust the positions at which the staples are driven into the end flaps of the cartons to accommodate varying width sizes of cartons fed thereto within the size range which is accommodated. This variation in the stapling positions is accomplished by sensing the particular width size of the carton fed to the machine through the normal operation of the belt assemblies 14 and of utilizing the sensed width to vary the position of components of the electropneumatic circuitry which determine the stapling positions.

The utilization of the measurement of the width size is possible when dealing with standard cartons since the longitudinal extent of the end flaps when in closed position is a direct function of the width size of the carton. Thus, this dimension of each end flap is equal to the transverse extent of the side flaps when folded and this extent of the side flaps is equal to approximately one-half of the width. Consequently, the area within which the staples are to be driven into the closed carton is limited to an area adjacent each end of the carton which extends inwardly from the carton end a distance equal to substantially onehalf of the width of the carton. The circuitry of the present invention is operable to proportionately move the instrumentalities which determine the stapling position in response to the sensing of the width of the carton being fed to the machine. The circuitry is also operable to vary 

